WO2011024548A1 - 内燃機関用スパークプラグ及びその製造方法 - Google Patents
内燃機関用スパークプラグ及びその製造方法 Download PDFInfo
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- WO2011024548A1 WO2011024548A1 PCT/JP2010/060624 JP2010060624W WO2011024548A1 WO 2011024548 A1 WO2011024548 A1 WO 2011024548A1 JP 2010060624 W JP2010060624 W JP 2010060624W WO 2011024548 A1 WO2011024548 A1 WO 2011024548A1
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- WIPO (PCT)
- Prior art keywords
- spark plug
- intermediate portion
- metal shell
- axis
- thin
- Prior art date
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- 238000000034 method Methods 0.000 title claims description 25
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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
- H01T13/00—Sparking plugs
- H01T13/20—Sparking plugs characterised by features of the electrodes or insulation
- H01T13/36—Sparking plugs characterised by features of the electrodes or insulation characterised by the joint between insulation and body, e.g. using cement
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02P—IGNITION, OTHER THAN COMPRESSION IGNITION, FOR INTERNAL-COMBUSTION ENGINES; TESTING OF IGNITION TIMING IN COMPRESSION-IGNITION ENGINES
- F02P13/00—Sparking plugs structurally combined with other parts of internal-combustion engines
-
- 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
Definitions
- the present invention relates to a spark plug used for an internal combustion engine and a manufacturing method thereof.
- the spark plug is attached to an internal combustion engine (engine), for example, and is used for ignition of the air-fuel mixture in the combustion chamber.
- a spark plug is an insulator having a shaft hole, a center electrode inserted through the tip end of the shaft hole, a metal shell provided on the outer periphery of the insulator, and a tip of the metal shell. And a ground electrode that forms a spark discharge gap with the electrode.
- the metal shell is pressed against the engine head of the internal combustion engine directly or indirectly through a gasket or the like, and a tool engaging portion to which a tool or the like is locked when attached to the internal combustion engine or the like. And a seat.
- the metal shell and the insulator are assembled by caulking and fixing. More specifically, a load along the axial direction is applied to the opening on the rear end side of the metal shell by an annular mold while an insulator is inserted in the cylindrical metal shell. Thereby, the rear end side opening of the metal shell is bent toward the inside in the radial direction and becomes a crimped portion that is locked to the large-diameter portion that bulges out in the radial direction of the insulator.
- the bracket and the insulator are assembled.
- thermal caulking is known as one method of caulking and fixing (see, for example, Patent Document 1). That is, while applying a load by the mold, the metal shell is energized and heated through the mold, and a relatively thin intermediate portion located between the tool engaging portion and the seat portion of the metal shell is heated. When the deformation resistance of the intermediate portion becomes small, the intermediate portion is buckled and deformed by the load. Thereafter, the intermediate portion in the thermally expanded state is cooled and contracted, so that the crimped portion of the metal shell is firmly locked to the large-diameter portion of the insulator. The metal fitting is firmly assembled.
- the present invention has been made in view of the above circumstances, and its purpose is to prevent the formation of recesses by causing the intermediate portion to bulge both radially outside and inside, and consequently stress corrosion in the intermediate portion. It is an object of the present invention to provide a spark plug and a method for manufacturing the same that can more reliably prevent the occurrence of cracks.
- a spark plug for an internal combustion engine of this configuration includes a cylindrical insulator extending in the axial direction, A cylindrical metal shell fixed to the outer periphery of the insulator; The metallic shell is A buttock bulging radially outward; A tool engaging portion to which a tool for mounting an internal combustion engine is engaged; An intermediate portion located between the flange portion and the tool engaging portion, The intermediate portion is a spark plug for an internal combustion engine having a bulging portion that bulges both radially inside and radially outside, The intermediate portion is a portion located on the rear end side in the axial direction with respect to the bulging portion, the first thin portion being the thinnest portion of the portion, and the bulging portion of the intermediate portion.
- the bulging portion has a most bulging portion which is a portion bulging most radially inward, In a cross section including the axis, The distance between the first thin portion and the second thin portion along the axis is F (mm), The bulge inward in the radial direction of the most bulged portion with respect to a virtual line connecting a portion positioned radially inward of the first thin portion and a portion positioned radially inward of the second thin portion.
- G mm
- the intermediate portion has a shape that bulges inward in the radial direction, formation of a recess in the inner peripheral portion can be suppressed, and stress corrosion cracking in the inner peripheral portion of the intermediate portion can be suppressed. Occurrence can be prevented more reliably.
- G / F ⁇ 0.18 is set, and the bulging portion of the intermediate portion is prevented from excessively bulging radially inward with respect to the length of the intermediate portion along the axis. . Therefore, an extreme increase in shrinkage stress applied to the intermediate portion can be suppressed, and as a result, further occurrence of stress corrosion cracking can be suppressed.
- the bulged portion needs to have no concave portion that can be a starting point of stress corrosion cracking in the inner peripheral portion. Therefore, as shown in FIG. 6, even if the bulging portion 71 bulges both radially inward and radially outward, it is not preferable that the concave portion 72 is formed in the inner peripheral portion.
- the spark plug for an internal combustion engine of this configuration is characterized in that, in the above configuration 1, 0.00 ⁇ G / F ⁇ 0.15 is satisfied.
- the spark plug for an internal combustion engine of this configuration is the above-described configuration 1 or 2, wherein the first thin portion has a Vickers hardness of E1 (Hv), the second thin portion has a Vickers hardness of E2 (Hv), and the most bulged portion When the Vickers hardness of E3 is E3 (Hv), at least one of the following formulas (2) and (3) is satisfied.
- the intermediate part will be cooled after the electric heating, but depending on the cooling conditions, the intermediate part will be in the state of being quenched and annealed, resulting in a difference in hardness in each part of the intermediate part There is a risk that.
- stress concentrates on the portion where the hardness difference is generated, so that stress corrosion cracking is more likely to occur.
- the spark plug for an internal combustion engine according to this configuration is the smaller of the cross-sectional area of the first thin portion and the cross-sectional area of the second thin portion in the cross section perpendicular to the axis in any of the first to third configurations.
- H cross-sectional area
- the smaller one of the cross-sectional area of the first thin portion and the cross-sectional area of the second thin portion is 35 mm 2. Since it is made relatively small as described below, the occurrence of stress corrosion cracking is further concerned, but the concern can be eliminated by adopting the above-described configuration 1 or the like. In other words, it can be said that the configuration 1 and the like are particularly significant when the intermediate portion is formed relatively thin. Note that the configuration 1 and the like work more effectively as the intermediate portion is thinner as in configurations 5 to 7 described below.
- the spark plug for an internal combustion engine of this configuration is characterized in that, in the above configuration 4, H ⁇ 31.2.
- the cross-sectional area of the thinnest portion of the intermediate portion is 31.2 mm 2, and there is a greater concern about the occurrence of stress corrosion cracking. Generation of cracks can be effectively suppressed.
- the occurrence of stress corrosion cracking is further concerned, but by employing the above configuration 1 or the like, the occurrence of stress corrosion cracking can be suppressed very effectively.
- a manufacturing method of the spark plug of this configuration includes a cylindrical insulator extending in the axial direction, A cylindrical metal shell fixed to the outer periphery of the insulator;
- the metal shell is a spark plug manufacturing method comprising an intermediate portion having a curved outer peripheral surface that bulges radially outward, When the insulator and the metal shell are fixed, a pressing force along the axial direction is applied to the rear end portion of the metal shell while the insulator is inserted through the metal shell.
- the insulating portion is formed by compressing and deforming the intermediate portion by energizing and heating at least the intermediate portion, and bending the rear end opening of the metal shell radially inward to form a crimped portion.
- Q (N) is the pressing force when the temperature of the portion that bulges most radially outward in the intermediate portion reaches 600 ° C.
- the pressing force when the current value of 50% of the current value applied to the intermediate portion is applied is P (N ) P ⁇ Q It is characterized by satisfying.
- the intermediate portion has a shape that tends to bulge outward in the radial direction after the deformation starts (for example, a minute amount outward in the radial direction).
- the shape may be bent. Therefore, if the intermediate portion is heated to a temperature at which the intermediate portion can be deformed in this state, the intermediate portion may bulge only outward in the radial direction.
- the pressing force P applied before the start of buckling deformation is relatively small, it is possible to more reliably prevent the intermediate portion from being easily bulged outward in the radial direction before the start of deformation.
- the intermediate portion can bulge not only radially outward but also radially inward, and as a result, formation of a recess in the inner peripheral portion of the intermediate portion can be suppressed.
- the occurrence of stress corrosion cracking in the intermediate portion can be prevented more reliably, and as a result, excellent airtightness and durability can be realized in the manufactured spark plug.
- the spark plug manufacturing method of the present configuration is characterized in that, in the above-described configuration 8, P ⁇ 0.8Q is satisfied.
- the intermediate portion can be more reliably bulged both radially outward and inside. As a result, excellent airtightness and durability can be realized more reliably.
- the spark plug manufacturing method of this configuration is characterized in that, in the above configuration 8 or 9, the temperature of the intermediate part at the start of deformation of the intermediate part is set to 350 ° C. or higher and 1100 ° C. or lower.
- the deformation of the intermediate part is started when the intermediate part is sufficiently heated to 350 ° C. or higher. Accordingly, the intermediate portion can be more reliably bulged inward in the radial direction, and the occurrence of stress corrosion cracking can be more reliably prevented.
- the temperature of the intermediate part at the start of deformation of the intermediate part is preferably 1100 ° C. or lower.
- the spark plug manufacturing method of this configuration is the metal shell according to any one of the above configurations 8 to 10, wherein a cylindrical mold having a curved surface corresponding to the caulking portion moves along the axis.
- the pressing force is applied to the rear end of When a portion of the mold that contacts the metal shell is projected onto a plane orthogonal to the axis, and the area of the projected portion is S (mm 2 ), P / S ⁇ 5 (N / mm 2 ) It is characterized by satisfying.
- P / S ⁇ 5 is satisfied for the projection area S that indirectly indicates the area of the mold that contacts the metal shell and the pressing force P applied from the mold to the metal shell. Both are set to satisfy. Therefore, since the mold and the metal shell come into contact with each other with a relatively large pressure, it is possible to prevent electric discharge between the mold and the metal shell, and more reliable energization from the mold to the metal shell can be achieved. As a result, the intermediate portion can be more reliably deformed into an intended shape that bulges both radially outside and inside by caulking.
- the spark plug manufacturing method of this configuration is characterized in that, in any one of the above configurations 8 to 11, the maximum temperature of the intermediate portion during the energization heating is set to 600 ° C. or more and 1300 ° C. or less.
- the intermediate portion since the intermediate portion is heated to a temperature at which it can be easily deformed, the intermediate portion can be more reliably deformed.
- the intermediate portion by heating the intermediate portion to 600 ° C. or higher, residual stress due to thermal shrinkage can be sufficiently generated in the intermediate portion, and airtightness as a spark plug can be sufficiently ensured.
- the heating temperature of the intermediate portion by setting the heating temperature of the intermediate portion to 1300 ° C. or lower, it is possible to prevent the intermediate portion from being too soft, and more reliably prevent damage (cracking) and instability of the shape of the intermediate portion. be able to.
- the spark plug manufacturing method of this configuration is characterized in that, in any one of the above configurations 8 to 12, a deformation amount of the intermediate portion along the axis is 0.2 mm or more and 1.0 mm or less.
- the intermediate portion since the deformation amount along the axis of the intermediate portion is 0.2 mm or more, the intermediate portion can sufficiently bulge inward in the radial direction, and in the inner peripheral portion of the intermediate portion The formation of the recess can be effectively suppressed.
- the amount of deformation along the axis of the intermediate portion is 1.0 mm or less, it is possible to more reliably prevent the intermediate portion from excessively bulging and excessive stress remaining in the intermediate portion. . As a result, combined with the ability to suppress the formation of the recesses, the occurrence of stress corrosion cracking can be more effectively suppressed.
- the spark plug manufacturing method of this configuration controls the pressing force applied to the rear end portion of the metal shell based on the amount of deformation along the axis of the intermediate portion in any of the above configurations 8 to 13. It is characterized by that.
- the intermediate portion can be more reliably deformed into a desired shape. As a result, excellent durability and airtightness can be more reliably realized in the manufactured spark plug.
- the spark plug manufacturing method of this configuration is the axis of the jig that presses the rear end portion of the metal shell based on the amount of deformation along the axis of the intermediate portion in any of the above configurations 8 to 13. The amount of movement along is controlled.
- the intermediate portion can be more reliably deformed into a desired shape, and as a result, the durability and airtightness of the manufactured spark plug can be improved more reliably.
- FIG. 1 is a partially broken front view showing a spark plug (hereinafter referred to as “spark plug”) 1 for an internal combustion engine.
- spark plug a spark plug 1 for an internal combustion engine.
- 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.
- 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 radially outward on the side, a middle body portion 12 that is smaller in diameter than the large-diameter portion 11, and a tip portion that is more distal than the middle body portion 12.
- a leg length part 13 formed with a smaller diameter than this is provided.
- the large diameter portion 11, the middle trunk portion 12, and most of the leg long portions 13 are accommodated inside the metal shell 3.
- a tapered step portion 14 that tapers toward the front end side in the axis CL1 direction is formed at the connecting portion between the leg length portion 13 and the middle trunk portion 12, and the insulator 2 is formed of the metal shell at the step portion 14. 3 is locked.
- a shaft hole 4 is formed through the insulator 2 along the axis CL1, and a center electrode 5 is inserted and fixed at the tip side of the shaft hole 4.
- 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, the center electrode 5 has a rod shape (cylindrical shape) as a whole, and a tip portion thereof protrudes from the tip of the insulator 2. Further, a columnar noble metal tip 31 formed of a noble metal alloy (for example, iridium alloy) is joined to the tip of the center electrode 5.
- a noble metal alloy for example, iridium alloy
- 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.
- 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.
- 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. Further, a flange 16 that bulges radially outward 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 spark plug 1 is attached to the engine head is provided. A caulking portion 20 for holding the insulator 2 is provided.
- the spark plug 1 has a relatively small diameter (for example, the screw diameter of the screw portion 15 is equal to or smaller than M12), and the metal shell 3 is also reduced in diameter.
- a stepped portion 21 is provided on the inner peripheral surface of the metal shell 3 so as to taper toward the tip end side of the axis CL1 for locking the insulator 2.
- the insulator 2 is inserted from the rear end side to the front end side of the metal shell 3, and the so-called heat caulking is performed in a state where its own step 14 is locked to the step 21 of the metal shell 3.
- the intermediate portion 41 is buckled and deformed, and is held by the metal shell 3 by forming the crimped portion 20.
- the caulking portion 20 is locked to the shoulder portion 23 in a shape that follows the shoulder portion 23 that forms a step shape located on the rear end side of the large diameter portion 11.
- An annular plate packing 22 is interposed between the two stepped portions 14 and 21.
- a ground electrode 27 made of a Ni alloy and having its substantially middle portion bent back is joined to the front end surface 26 of the metal shell 3.
- a columnar noble metal tip 32 made of a noble metal alloy (for example, platinum alloy) is joined to the tip of the ground electrode 27, and the tip surface of the noble metal tip 32 faces the tip surface of the noble metal tip 31. ing.
- a spark discharge gap 33 is formed between the noble metal tips 31 and 32, and the spark discharge is performed in the spark discharge gap 33 in a direction substantially along the axis CL1.
- the intermediate part 41 has a bulging part 42, a first thin part 43, and a second thin part 44.
- the bulging portion 42 is formed in the central portion 41 of the intermediate portion 41 in the substantially central portion, and has a shape that bulges both radially inward and outward.
- the first thin portion 43 is located on the rear end side of the bulging portion 42 in the axis CL1 direction, and is the most among the portions located on the rear end side of the bulging portion 42 in the intermediate portion 41. It is thin.
- the second thin portion 44 is located on the distal end side of the bulging portion 42 in the axis CL1 direction, and is formed to be the thinnest among the portions located on the distal end side of the bulging portion 42 in the intermediate portion 41. .
- the distance between the first thin portion 43 and the second thin portion 44 along the direction of the axis CL1 is F (mm), and the part IP1 located on the innermost radial direction of the first thin portion 43 and the second thin portion
- the intermediate portion 41 is formed so as to satisfy 0.00 ⁇ G / F ⁇ 0.18, where G is (mm).
- H ⁇ 35 is set, where H (mm 2 ) is the smaller cross-sectional area of the cross-sectional areas of the first thin portion 43 and the second thin portion 44. Yes. That is, as the diameter of the metal shell 3 is reduced, the intermediate portion 41 is formed relatively thin.
- the intermediate portion 41 is energized and heated during a caulking step (heat caulking) described later, but is naturally cooled after the energization heating. Therefore, depending on the speed at which the intermediate portion 41 is cooled, the intermediate portion 41 can be in a state where it has been quenched or annealed. In the present embodiment, when the intermediate portion 41 is cooled, no special temperature adjustment is performed, and as a result, a relatively large hardness difference may occur in each portion of the intermediate portion 41.
- the Vickers hardness of the first thin portion 43 is E1 (Hv)
- the Vickers hardness of the second thin portion 44 is E2 (Hv)
- the Vickers hardness of the most bulged portion 42M is E3 ( Hv)
- the intermediate portion 41 can be formed so as to satisfy at least one of 20 ⁇
- the insulator 2 is molded.
- a raw material powder mainly composed of alumina and containing a binder or the like a green granulated material for molding is prepared, and rubber press molding is used to obtain a cylindrical molded body.
- the insulator 2 is obtained by subjecting the obtained molded body to grinding and shaping the outer shape, followed by firing.
- the central electrode 5 is manufactured separately from the insulator 2. That is, the center electrode 5 is produced by forging a Ni alloy in which a copper alloy for improving heat dissipation is arranged at the center. Next, the noble metal tip 31 is joined to the tip surface of the center electrode 5 by laser welding or the like.
- the insulator 2 and the center electrode 5, the resistor 7, and the terminal electrode 6 obtained as described above are sealed and fixed by the glass seal layers 8 and 9, so that the center electrode is attached to the insulator 2. 5 is attached.
- the glass seal layers 8 and 9 are generally prepared by mixing borosilicate glass and metal powder, and the prepared material is injected into the shaft hole 4 of the insulator 2 with the resistor 7 interposed therebetween.
- the terminal electrode 6 is pressed from behind, and then baked in a baking furnace.
- the glaze layer may be fired simultaneously on the surface of the rear end body portion 10 of the insulator 2 or the glaze layer may be formed in advance.
- the metal shell 3 is processed in advance. That is, a through hole is formed in a cylindrical metal material (for example, an iron-based material such as S17C or S25C or a stainless steel material) by cold forging to form a rough shape. Then, while trimming, the external shape is adjusted, and the threaded portion 15 is formed by rolling at a predetermined portion to obtain a metal shell intermediate. Further, the metal shell intermediate is galvanized or nickel plated. In order to improve the corrosion resistance, the surface may be further subjected to chromate treatment.
- a cylindrical metal material for example, an iron-based material such as S17C or S25C or a stainless steel material
- a straight rod-shaped ground electrode 27 is resistance-welded to the front end surface of the metal shell intermediate body.
- so-called “sag” is generated.
- the threaded portion 15 is formed by rolling at a predetermined portion of the metal shell intermediate body.
- the metal shell 3 to which the ground electrode 27 is welded is obtained.
- the metal shell 3 to which the ground electrode 27 is welded is galvanized or nickel plated.
- the surface may be further subjected to chromate treatment. After the plating process is performed, the plating covering at least the portion corresponding to the bent portion of the ground electrode 27 is removed.
- the insulator 2 provided with the center electrode 5 and the terminal electrode 6 and the metal shell 3 provided with the ground electrode 27, which are respectively prepared as described above, are fixed.
- so-called heat caulking is performed. That is, as shown in FIG. 3A, the metallic shell 3 is held by the second mold 52 by inserting the distal end side of the metallic shell 3 into the second mold 52.
- the intermediate portion 41 does not bulge outward and inward in the radial direction, and has a cylindrical shape.
- the first mold 51 is mounted from above the metal shell 3.
- the first mold 51 has a cylindrical shape and includes a caulking forming portion 51 f having a curved surface corresponding to the shape of the caulking portion 20.
- the first mold 51 has an area of the projected portion when a portion that contacts the metal shell 3 during the caulking process is projected onto a plane perpendicular to the axis CL1 along the direction of the axis CL1. Is formed to have a predetermined area S (for example, 90 mm 2 ).
- the metal shell 3 (intermediate portion 41) is energized and heated by a predetermined power supply device (not shown) through the first mold 51, the first and second molds 51 and 52 are used to The metal shell 3 is sandwiched and a predetermined pressing force is applied to the metal shell 3 along the direction of the axis CL1. Thereby, the rear end side opening part of the metal shell 3 is caulked inward in the radial direction, and the caulking part 20 is formed.
- the intermediate portion 41 is heated to a predetermined temperature (for example, 350 ° C. or more and 1100 ° C. or less) by energization, and the deformation resistance of the intermediate portion 41 becomes relatively small, the pressing force applied from both the molds 51 and 52 is increased.
- the buckling deformation of the intermediate portion 41 is started by the pressure.
- both the molds 51 and 52 are controlled so that the pressing force applied to the metal shell 3 is gradually increased until the buckling deformation of the intermediate portion 41 is completed.
- the pressing force is Q ( N)
- the temperature of the portion of the intermediate portion 41 that bulges most outward in the radial direction is 600 ° C., and is 50% of the current applied when the portion reaches 600 ° C.
- P ⁇ Q for example, P ⁇ 0.8Q
- P (N) is the pressing force when the voltage is applied (in other words, when energization is started)
- the pressing force is controlled.
- the deformed intermediate portion 41 is buckled and deformed so as to bulge not only radially outward but also radially outward and inward.
- the pressing force applied from the molds 51 and 52 to the metal shell 3 is controlled based on the deformation amount of the intermediate portion 41 along the axis CL1.
- the amount of deformation along the axis CL1 of the portion 41 is set to 0.2 mm or more and 1.0 mm or less.
- the intermediate portion 41 is energized and heated so that its maximum temperature is 600 ° C. or higher and 1300 ° C. or lower.
- the intermediate portion 41 that has been in a thermally expanded state is naturally cooled, so that the intermediate portion 41 contracts in the direction of the axis CL1 and is fastened to the shoulder portion 23. 20 will press the shoulder 23 toward the tip side.
- the stepped portion 14 formed on the outer peripheral surface of the insulator 2 and the stepped portion 21 formed on the inner peripheral surface of the metal shell 3 are firmly locked.
- the insulator 2 and the metal shell are connected. 3 is firmly fixed.
- the noble metal tip 32 is joined to the tip of the ground electrode 27 by resistance welding or the like. Finally, the above-described spark plug 1 is obtained by bending the ground electrode 27 toward the center electrode 5 and adjusting the size of the spark discharge gap 33 between the two noble metal tips 31 and 32.
- the buckling deformation of the intermediate portion 41 occurs when the temperature of the portion of the intermediate portion 41 that bulges most outward in the radial direction reaches 600 ° C. (in other words, the buckling deformation of the intermediate portion 41 occurs).
- the pressing force when almost finished is Q
- a current value of 50% of the current value applied to the intermediate portion 41 is applied when the portion reaches 600 ° C. (in other words, energization starts)
- the pressing force applied to the metal shell 3 is controlled so as to satisfy P ⁇ Q, where P is the pressing force at the time. That is, the caulking process is performed so that the pressing force increases from the start of energization to the end of the buckling deformation of the intermediate portion 41.
- the pressing force applied before the start of buckling deformation is relatively small, it is possible to more reliably prevent the intermediate portion 41 from becoming a shape that tends to bulge outward in the radial direction before the start of deformation.
- the intermediate part 41 can be bulged not only in the radial direction but also in the radial direction, and as a result, formation of a recess in the inner peripheral part of the intermediate part 41 can be suppressed.
- the deformation of the intermediate part 41 is started when the intermediate part 41 is sufficiently heated to 350 ° C. or higher. Accordingly, the intermediate portion 41 can be more reliably bulged inward in the radial direction, and the occurrence of stress corrosion cracking can be more reliably prevented.
- the temperature of the intermediate part at the start of deformation is less than 1100 ° C., it is possible to prevent electric discharge from occurring between the metal shell 3 and the first mold 51, and the caulking process is not hindered. It can be carried out.
- a projection area S (mm 2 ) that indirectly indicates the area of the first metal mold 51 that contacts the metal shell 3 and a pressing force P (N) applied from the metal mold to the metal shell are set to satisfy P / S ⁇ 5 (N / mm 2 ). Accordingly, since the first mold 51 and the metal shell 3 come into contact with each other with a relatively large pressure, the discharge between the first metal mold 51 and the metal shell 3 can be prevented. More reliable energization of the metal fitting 3 can be achieved. As a result, the intermediate part 41 can be more reliably deformed into an intended shape that bulges both radially outward and inside by caulking.
- the intermediate portion 41 since the maximum temperature of the intermediate portion 41 at the time of energization heating is set to 600 ° C. or higher and 1300 ° C. or lower, the intermediate portion 41 can be more reliably and more easily deformed.
- the intermediate portion 41 can be sufficiently bulged inward in the radial direction, and the concave portion in the inner peripheral portion of the intermediate portion 41 Can be effectively suppressed.
- the amount of deformation along the axis CL1 of the intermediate portion 41 is 1.0 mm or less, the intermediate portion 41 is excessively swelled and excessive stress remains in the intermediate portion 41. This can surely prevent the occurrence of stress corrosion cracking and can be more effectively suppressed.
- the intermediate portion 41 can be more reliably deformed into a desired shape.
- the intermediate portion 41 has a shape that bulges in both the radially inner side and the outer side (that is, 0.00 ⁇ G / F ⁇ 0.18). Even under conditions where corrosion cracking is likely to occur, the occurrence of stress corrosion cracking can be effectively prevented.
- the spark plug 1 is reduced in diameter as in the present embodiment, the smaller one of the cross-sectional area of the first thin portion 43 and the cross-sectional area of the second thin portion 44 is compared with 35 mm 2 or less.
- the intermediate portion 41 is made relatively thin by forming the intermediate portion 41 in the above-described shape, the stress corrosion cracking may occur. Can be more reliably prevented.
- the outline of the corrosion cracking evaluation test is as follows. That is, while changing the length along the axis of the intermediate portion before deformation, by changing the applied load, the energization condition, etc., and performing caulking, the distance F between the two thin portions along the axis is Samples of the spark plugs with various changes in the bulge amount G of the bulge portion relative to the imaginary line connecting the innermost peripheral portions of both thin portions (that is, with various values of G / F changed) Twenty pieces were produced.
- the middle portion is bulged not only radially outward but also radially inward, that is, G / It can be said that it is desirable to form the intermediate portion so as to satisfy F> 0.00.
- the intermediate portion bulges outward in the radial direction, excessive stress remains in the intermediate portion, which may lead to stress corrosion cracking.
- the intermediate portion in order to more reliably prevent the occurrence of stress corrosion cracking, it is more preferable to form the intermediate portion so as to satisfy 0.00 ⁇ G / F ⁇ 0.18, and 0.00 ⁇ G / F ⁇ It can be said that it is more preferable to form the intermediate portion so as to satisfy 0.15.
- FIG. 4 is a graph showing the relationship between the hardness difference and the effect rate.
- the “hardness difference” means a value having a larger absolute value among “E3-E1” and “E3-E2”.
- the effect ratio the larger the value, the more effective the G / F is from 0.00 to G / F is 0.10 (that is, the effect is expanded radially inward). It means big.
- the effect by having set G / F to 0.00 is effectively exhibited, so that the cross-sectional area H is small. That is, as shown in FIG. 4, the effect of suppressing cracking by increasing G / F to greater than 0.00 is more prominent when the cross-sectional area H is 31.2 mm 2 or less. the further remarkably exhibited when the 26.4 mm 2 or less, it can be said to be very remarkably exhibited when the cross-sectional area H was 19.4 mm 2 or less.
- the intermediate portion bulges inward in the radial direction when a relatively large hardness difference of 20 Hv or more occurs in the intermediate portion or the cross-sectional area H is relatively small as 35 mm 2 or less. It can be said that the effect by carrying out is exhibited notably.
- the pressing force Q (N) when the temperature of the portion that bulges most radially outward in the intermediate portion becomes 600 ° C. (when the buckling deformation of the intermediate portion is almost finished) is made constant.
- the temperature of the most bulging portion on the outer side in the radial direction is a stage before the temperature reaches 600 ° C., and the current of 50% of the maximum amplitude of the current applied when the portion reaches 600 ° C.
- the pressing force P (N) when applied (when energization was started) was variously changed, and the caulking process was performed, so that a plurality of 20 spark plug samples were produced.
- the intermediate part was observed, and the cross-sectional shape of the intermediate part was specified.
- the intermediate portion bulges both radially inward and outward, it is possible to form a preferable shape at a very high rate in terms of preventing stress corrosion cracking.
- a favorable shape is formed in terms of preventing stress corrosion cracking. It was decided to evaluate “ ⁇ ” as possible.
- the intermediate part may be formed in a shape that bulges both radially inward and outward. It was decided to give an "X" rating as difficult.
- Table 6 shows the pressing forces P and Q and the evaluation.
- the pressing force P and the size of the first metal fitting are set so that P / S ⁇ 5 (N / mm 2 ). It can be said that it is preferable to set the thickness or set the temperature of the intermediate part at the start of deformation to 350 ° C. or higher and 1100 ° C. or lower.
- the temperature when the deformation of the intermediate portion 41 starts is 350 ° C. or more and 1100 ° C. or less, but the temperature when the deformation of the intermediate portion 41 starts is limited to this. is not.
- the deformation amount along the axis CL1 of the intermediate portion 41 is set to 0.2 mm or more and 1.0 mm or less, and the maximum temperature of the intermediate portion 41 is 600 ° C. or more and 1300 ° C. or less.
- the amount of deformation along the axis CL1 of the intermediate portion 41 and the maximum temperature of the intermediate portion 41 are not limited to the above ranges.
- the pressing force applied from the molds 51 and 52 to the metal shell 3 is controlled based on the deformation amount of the intermediate portion 41 along the axis CL1, but the pressing force control method Is not limited to this.
- the smaller one of the cross-sectional area of the first thin part 43 and the cross-sectional area of the second thin part is set to 35 mm 2 or less as the spark plug 1 is reduced in diameter.
- the cross-sectional areas of the thin portions 43 and 44 are not particularly limited. According to the present invention, even when the cross-sectional areas of the thin portions 43 and 44 are relatively large, the occurrence of stress corrosion cracking can be effectively prevented.
- 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.
- it may be a Bi-HEX (deformed 12-angle) shape [ISO 22777: 2005 (E)].
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Abstract
Description
前記絶縁体の外周に固定された筒状の主体金具とを備え、
前記主体金具は、
径方向外側に膨出する鍔部と、
内燃機関取付けのための工具が係合される工具係合部と、
前記鍔部及び前記工具係合部の間に位置する中間部とを具備し、
前記中間部は、径方向内側及び径方向外側の双方に膨出する膨出部を有する内燃機関用スパークプラグであって、
前記中間部は、前記膨出部よりも前記軸線方向後端側に位置する部位であり、当該部位のうち最も薄肉の部位である第1薄肉部と、前記中間部のうち前記膨出部よりも前記軸線方向先端側に位置する部位であり、当該部位のうち最も薄肉の部位である第2薄肉部とを有し、
前記膨出部は、最も径方向内側に膨出している部位である最膨出部を有し、
前記軸線を含む断面において、
前記軸線に沿った前記第1薄肉部及び前記第2薄肉部間の距離をF(mm)とし、
前記第1薄肉部のうち最も径方向内側に位置する部位と前記第2薄肉部のうち最も径方向内側に位置する部位とを結ぶ仮想線に対する、前記最膨出部の径方向内側への膨出量をG(mm)としたとき、
次の式(1)を満たすことを特徴とする。
上記構成1によれば、中間部が径方向内側へと膨出する形状をなしているため、内周部分における凹部の形成を抑制することができ、中間部の内周部分における応力腐食割れの発生をより確実に防止することができる。
20≦|E2-E3|…(3)
中間部は通電加熱後に冷却されることとなるが、冷却の条件によっては、中間部は焼き入れや焼き鈍しを行われたような状態となり、その結果、中間部の各部位に硬度差が生じてしまうおそれがある。ここで、中間部に比較的大きな硬度差が生じている場合には、硬度差の生じている箇所に応力が集中するため、応力腐食割れがより生じてしまいやすい。
前記絶縁体の外周に固定された筒状の主体金具とを備え、
前記主体金具が、径方向外側に膨出する湾曲面状の外周面を有する中間部を具備するスパークプラグの製造方法であって、
前記絶縁体と前記主体金具とを固定する際には、前記主体金具に前記絶縁体を挿通させた状態で、前記主体金具の後端部に対して前記軸線方向に沿った押圧力を加えつつ、少なくとも前記中間部を通電加熱することにより、前記中間部を圧縮させ潰れ変形させるとともに、前記主体金具の後端開口部を径方向内側に屈曲させて加締め部を形成することで、前記絶縁体と前記主体金具とを固定し、
前記押圧力のうち、
前記中間部のうち径方向外側に最も膨出する部位の温度が600℃となったときの押圧力をQ(N)とし、
前記部位が600℃となる前段階であって、前記部位が600℃となったときにおいて前記中間部に印加される電流値の50%の電流値が印加されたときの押圧力をP(N)としたとき、
P<Q
を満たすことを特徴とする。
前記金型のうち前記主体金具に接触する部分を前記軸線と直交する平面に投影し、当該投影された部分の面積をS(mm2)としたとき、
P/S≧5(N/mm2)
を満たすことを特徴とする。
2…絶縁体(絶縁碍子)
3…主体金具
16…鍔部
19…工具係合部
20…加締め部
41…中間部
42…膨出部
42M…最膨出部
43…第1薄肉部
44…第2薄肉部
51…第1の金型(金型)
CL1…軸線
Claims (15)
- 軸線方向に延びる筒状の絶縁体と、
前記絶縁体の外周に固定された筒状の主体金具とを備え、
前記主体金具は、
径方向外側に膨出する鍔部と、
内燃機関取付けのための工具が係合される工具係合部と、
前記鍔部及び前記工具係合部の間に位置する中間部とを具備し、
前記中間部は、径方向内側及び径方向外側の双方に膨出する膨出部を有する内燃機関用スパークプラグであって、
前記中間部は、前記膨出部よりも前記軸線方向後端側に位置する部位であり、当該部位のうち最も薄肉の部位である第1薄肉部と、前記中間部のうち前記膨出部よりも前記軸線方向先端側に位置する部位であり、当該部位のうち最も薄肉の部位である第2薄肉部とを有し、
前記膨出部は、最も径方向内側に膨出している部位である最膨出部を有し、
前記軸線を含む断面において、
前記軸線に沿った前記第1薄肉部及び前記第2薄肉部間の距離をF(mm)とし、
前記第1薄肉部のうち最も径方向内側に位置する部位と前記第2薄肉部のうち最も径方向内側に位置する部位とを結ぶ仮想線に対する、前記最膨出部の径方向内側への膨出量をG(mm)としたとき、
次の式(1)を満たすことを特徴とする内燃機関用スパークプラグ。
0.00<G/F≦0.18…(1) - 0.00<G/F≦0.15を満たすことを特徴とする請求項1に記載の内燃機関用スパークプラグ。
- 前記第1薄肉部のビッカース硬度をE1(Hv)、前記第2薄肉部のビッカース硬度をE2(Hv)、前記最膨出部のビッカース硬度をE3(Hv)としたとき、次の式(2),(3)のうち少なくとも一方を満たすことを特徴とする請求項1又は2に記載の内燃機関用スパークプラグ。
20≦|E1-E3|…(2)
20≦|E2-E3|…(3) - 前記軸線と直交する断面において、前記第1薄肉部の断面積と前記第2薄肉部の断面積とのうち小さい方の断面積をH(mm2)としたとき、H≦35であることを特徴とする請求項1乃至3のいずれか1項に記載の内燃機関用スパークプラグ。
- H≦31.2であることを特徴とする請求項4に記載の内燃機関用スパークプラグ。
- H≦26.4であることを特徴とする請求項4に記載の内燃機関用スパークプラグ。
- H≦19.4であることを特徴とする請求項4に記載の内燃機関用スパークプラグ。
- 軸線方向に延びる筒状の絶縁体と、
前記絶縁体の外周に固定された筒状の主体金具とを備え、
前記主体金具が、径方向外側に膨出する湾曲面状の外周面を有する中間部を具備するスパークプラグの製造方法であって、
前記絶縁体と前記主体金具とを固定する際には、前記主体金具に前記絶縁体を挿通させた状態で、前記主体金具の後端部に対して前記軸線方向に沿った押圧力を加えつつ、少なくとも前記中間部を通電加熱することにより、前記中間部を圧縮させ潰れ変形させるとともに、前記主体金具の後端開口部を径方向内側に屈曲させて加締め部を形成することで、前記絶縁体と前記主体金具とを固定し、
前記押圧力のうち、
前記中間部のうち径方向外側に最も膨出する部位の温度が600℃となったときの押圧力をQ(N)とし、
前記部位が600℃となる前段階であって、前記部位が600℃となったときにおいて前記中間部に印加される電流値の50%の電流値が印加されたときの押圧力をP(N)としたとき、
P<Q
を満たすことを特徴とするスパークプラグの製造方法。 - P≦0.8Qを満たすことを特徴とする請求項8に記載のスパークプラグの製造方法。
- 前記中間部の変形開始時における前記中間部の温度を350℃以上1100℃以下としたことを特徴とする請求項8又は9に記載のスパークプラグの製造方法。
- 前記加締め部に対応する湾曲面を有する筒状の金型が前記軸線に沿って移動することにより、前記主体金具の後端部に対して前記押圧力が加えられ、
前記金型のうち前記主体金具に接触する部分を前記軸線と直交する平面に投影し、当該投影された部分の面積をS(mm2)としたとき、
P/S≧5(N/mm2)
を満たすことを特徴とする請求項8乃至10のいずれか1項に記載のスパークプラグの製造方法。 - 前記通電加熱時における前記中間部の最高温度を600℃以上1300℃以下としたことを特徴とする請求項8乃至11のいずれか1項に記載のスパークプラグの製造方法。
- 前記中間部の前記軸線に沿った変形量を0.2mm以上1.0mm以下としたことを特徴とする請求項8乃至12のいずれか1項に記載のスパークプラグの製造方法。
- 前記中間部の前記軸線に沿った変形量に基づいて、前記主体金具の後端部に加えられる押圧力を制御することを特徴とする請求項8乃至13のいずれか1項に記載のスパークプラグの製造方法。
- 前記中間部の前記軸線に沿った変形量に基づいて、前記主体金具の後端部を押圧する治具の前記軸線に沿った移動量を制御することを特徴とする請求項8乃至13のいずれか1項に記載のスパークプラグの製造方法。
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IN1487DEN2012 IN2012DN01487A (ja) | 2009-08-26 | 2010-06-23 | |
US13/392,351 US8519606B2 (en) | 2009-08-26 | 2010-06-23 | Spark plug for internal combustion engine and method of manufacturing spark plug |
JP2010544913A JP5092022B2 (ja) | 2009-08-26 | 2010-06-23 | 内燃機関用スパークプラグ及びその製造方法 |
EP10811599.9A EP2472682B1 (en) | 2009-08-26 | 2010-06-23 | Spark plug for internal combustion engine and method for manufacturing same |
KR1020127005094A KR101392040B1 (ko) | 2009-08-26 | 2010-06-23 | 내연엔진용 스파크 플러그 및 그 제조방법 |
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JP2003332021A (ja) | 2003-06-18 | 2003-11-21 | Ngk Spark Plug Co Ltd | スパークプラグ及びその製造方法 |
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EP1324446B1 (en) * | 2001-12-28 | 2007-10-31 | NGK Spark Plug Company Limited | Spark plug and method for manufacturing the spark plug |
US7164225B2 (en) * | 2003-09-11 | 2007-01-16 | Ngk Spark Plug Co., Ltd. | Small size spark plug having side spark prevention |
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EP1837964B1 (en) * | 2006-03-20 | 2014-02-12 | NGK Spark Plug Co., Ltd. | Spark plug for use in an internal-combustion engine |
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Also Published As
Publication number | Publication date |
---|---|
EP2472682B1 (en) | 2018-11-07 |
EP2472682A4 (en) | 2014-04-16 |
KR20120058528A (ko) | 2012-06-07 |
JP5092022B2 (ja) | 2012-12-05 |
KR101392040B1 (ko) | 2014-05-07 |
EP2472682A1 (en) | 2012-07-04 |
CN102598441A (zh) | 2012-07-18 |
US20120146484A1 (en) | 2012-06-14 |
CN102598441B (zh) | 2013-06-26 |
JPWO2011024548A1 (ja) | 2013-01-24 |
IN2012DN01487A (ja) | 2015-06-05 |
US8519606B2 (en) | 2013-08-27 |
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