WO2013015262A1 - 点火プラグ用クラッド電極及びその製造方法 - Google Patents
点火プラグ用クラッド電極及びその製造方法 Download PDFInfo
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- WO2013015262A1 WO2013015262A1 PCT/JP2012/068656 JP2012068656W WO2013015262A1 WO 2013015262 A1 WO2013015262 A1 WO 2013015262A1 JP 2012068656 W JP2012068656 W JP 2012068656W WO 2013015262 A1 WO2013015262 A1 WO 2013015262A1
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- metal tip
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- spark plug
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- clad electrode
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- 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
- H01T13/39—Selection of materials for electrodes
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- 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
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- 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
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- the present invention relates to an electrode (center electrode and ground electrode) of a spark plug, and more particularly to a clad electrode for a spark plug in which a noble metal tip and a base material are joined and a manufacturing method thereof.
- a so-called clad electrode in which a noble metal tip formed from a Pt alloy or an Ir alloy is bonded to a base material such as a Ni alloy or a Cu alloy is known as a center electrode of a spark plug used in an internal combustion engine or the like.
- the noble metal tip and the base material are different materials, and in joining, resistance welding or laser welding is used to ensure the joining stability (for example, patents) Reference 1).
- laser welding is often used because the joining strength cannot be satisfied only by resistance welding.
- This laser welding is a part where the noble metal tip and the base material are in contact with each other, and by irradiating the outer peripheral surface of the contacted part with a laser, the irradiated part is melted and the noble metal tip and the base material are joined. It is.
- this laser welding is a method in which the joint between the noble metal tip and the base material is melted and joined from the outer peripheral surface, there is a possibility that the inner part of the joint surface may be in an undissolved state, and at the joint interface. Voids may remain.
- cracks are generated by the expansion of the gas confined in the voids, and the noble metal tip tends to peel from the substrate.
- the use environment of spark plugs has become high, and there are many problems such as falling off of precious metal tips due to the effects of heat generation due to repeated discharge ignition and excessive cooling and heat cycle of heat dissipation, and the life of spark plugs has been shortened. It is pointed out that it runs out early.
- the width of the melting zone on the outer peripheral surface of the joining portion increases.
- This melting zone is a region formed by melting and solidifying a material, and its material structure is different from other parts, and is brittle and inferior in electrical properties. Therefore, the material of the molten zone is not effective as a plug material, and when the width increases, it is necessary to take extra length (thickness) of the noble metal tip. Therefore, it was not preferable from the viewpoint of cost or resource saving.
- the present invention has been made under the circumstances as described above, and in the clad electrode formed from the noble metal tip and the base material, the joining of the noble metal tip and the base material can be reliably maintained, and the length of the spark plug is increased. It is an object of the present invention to provide a manufacturing technique of a clad electrode which can achieve a long life and uses a noble metal tip having a minimum necessary length.
- the present invention provides a spark plug clad electrode used for an electrode of a spark plug comprising a noble metal tip disposed at a tip portion of a spark plug and a base material to which the noble metal tip is bonded.
- the bonding interface is substantially flat.
- the clad electrode for a spark plug of the present invention employs a joining process in which resistance welding and diffusion joining are continued instead of conventional laser welding for joining the noble metal tip and the base material.
- Diffusion bonding forms a diffusion layer over the entire surface at the bonding interface and is securely bonded, so that noble metal chips can be prevented from peeling off and falling off, and the life of the spark plug can be extended even in harsh usage environments. it can.
- the diffusion layer is smooth and uniform with little variation in thickness, and the bonding interface is substantially flat. The thickness of the diffusion layer can be controlled by the joining conditions, and thereby the length of the noble metal tip can be set to a minimum.
- the thickness of the diffusion layer is preferably 5 ⁇ m to 100 ⁇ m. When this thickness is less than 5 ⁇ m, sufficient bonding strength tends to be not obtained. When the thickness exceeds 100 ⁇ m, Ni-based alloys or Cu-based alloys that are weak against spark consumption (discharge consumption) tend to be present at a high concentration on the discharge surface (near), which tends to shorten the life of the spark plug. .
- this diffusion layer is formed by diffusing Ni or Cu to the noble metal tip side when using a base material, for example, a base material of Ni alloy or Cu alloy.
- the clad electrode for a spark plug according to the present invention may have an unjoined portion on the outer peripheral surface of the joined portion. Even if there is an unbonded portion on the outer peripheral surface, strong bonding is achieved inside, and the noble metal tip does not peel off. Moreover, this unjoined part can act as a buffer part which relieves the expansion / contraction difference when the thermal cycle generated between the noble metal tip and the base material is received in the joined part. In addition, the length (average value) of the unjoined portion is allowed up to a maximum length of 1/5 with respect to the radius of the noble metal tip.
- the precious metal tip in the present invention is preferably a Pt alloy or an Ir alloy.
- Specific examples include a Pt—Rh alloy, a Pt—Ir alloy, a Pt—Ni alloy, a Pt—Cu alloy, an Ir—Rh alloy, an Ir—Pt alloy, and an Ir—FeNiCr alloy.
- the base material in this invention is Ni alloy or Cu alloy.
- the joining surface of the substantially columnar noble metal tip is brought into contact with the surface of the base material, the noble metal tip is pre-joined to the base material surface by resistance welding, and the base material and the noble metal tip are bonded by heat treatment.
- the present invention relates to a clad electrode material in which a base material and a noble metal tip are integrated by diffusion bonding.
- the clad electrode for a spark plug according to the present invention abuts the surface of the base material on the surface of the base metal noble metal tip, pre-joins the base metal surface with the noble metal tip by resistance welding, and heat-treats the base material.
- a noble metal tip can be manufactured by diffusion bonding. In the conventional laser welding method, there is a tendency that the amount of noble metal used is increased because the noble metal tip is melted.
- a clad electrode can be formed with a necessary amount of noble metal.
- a preliminary bonding process is performed using a base material and a separately prepared noble metal tip, and a part in which the base material and the noble metal chip are integrated is punched, and then a thermal diffusion bonding process is performed.
- the resistance welding for the pre-joining is a pressing force of 5 to 10 kgf, a welding current of 500 to 1500 A, and an energization time of 2 to 200 msec.
- the characteristics of this pre-joining condition are high pressurization, low current, and long energization time, unlike general resistance welding.
- the heat treatment conditions for diffusion bonding are preferably 800 to 1200 ° C., 1 to 5 hours, and heat treatment in a vacuum, a reducing atmosphere, or an inert atmosphere.
- the heat treatment atmosphere is desirably an atmosphere in which the Ni-based alloy and the Cu-based alloy are not oxidized at high temperature.
- the pre-bonding pressure is weak, the contact area between the base material and the noble metal tip cannot be obtained, and a gap tends to be generated on the bonding surface. Further, if the applied pressure is strong, the noble metal tip is crushed and there is a tendency that an edge for improving the ignition performance as a spark plug cannot be obtained. If the pre-welding welding current is too high, voids are generated in the vicinity of the joining surface, and there is a high possibility that the noble metal tip will drop off in the actual usage environment due to the reduction in joining strength. It tends to occur and trigger an abnormal discharge.
- the energization time if the time is long, diffusion of the bonding interface also proceeds, but the production efficiency is lowered, and a product at a low cost tends not to be realized. If the pre-bonding energization time is short, thermal diffusion of atoms at the bonding interface does not proceed, and a sufficient diffusion layer tends not to be obtained even by the diffusion process in the next step.
- the present invention it is possible to reliably maintain the bonding between the noble metal tip and the base material and to extend the life of the spark plug.
- the method for manufacturing a clad electrode in the present invention since the material can be used efficiently, the manufacturing cost can be reduced.
- the cross-sectional schematic diagram which shows the manufacturing process of the clad electrode of this embodiment The cross-sectional schematic diagram which shows the manufacturing process of the clad electrode of this embodiment.
- the cross-sectional schematic diagram which shows the manufacturing process of the clad electrode of this embodiment The cross-sectional schematic diagram which shows the manufacturing process of the clad electrode of this embodiment.
- the perspective view of the clad electrode of this embodiment The cross-sectional observation photograph of the clad electrode (with an unjoined part) of this embodiment.
- FIGS. 1A to 1D are schematic cross-sectional views showing a manufacturing process of a grad electrode according to this embodiment.
- a cylindrical substrate made of a Pt—Rh 20% alloy having a diameter of 1.0 mm and a thickness of 0.3 mm is formed on a tape-like substrate 1 made of Ni—Ir 1% alloy and having a thickness of 0.3 mm.
- the noble metal tip 2 was disposed so as to be perpendicular to the substrate. When the noble metal tip 2 is brought into contact with the surface of the tape-like base material 1, the noble metal tip is perpendicular to the base material, a gap between the contact surface of the noble metal tip and the substrate surface, It was made not to have a state such as a piece hit.
- resistance welding electrodes (3, 3 ′) are connected to the base material 1 and the noble metal tip 2, respectively, under the conditions of a pressing force of 7 kgf, a welding current of 1350 A, and an energization time of 9 msec. Resistance welding was performed and preliminary joining was performed. In this embodiment, two types of pre-joined clad materials were manufactured by changing the resistance welding conditions.
- FIG. 1C After performing the preliminary joining process, as shown in FIG. 1C, punching was performed on the pre-joined portion using a punching punch 4 having a predetermined diameter and a punching die 5 corresponding thereto. Thereafter, the base material 1 and the noble metal chip 2 were heat-treated in a vacuum electric furnace under the conditions of a heating temperature of 1100 ° C. for 1 hour. By this heat treatment, as shown in FIG. 1D, it was confirmed by cross-sectional observation that a diffusion layer 6 having a thickness of 30 ⁇ m was formed and diffusion bonding was performed.
- FIG. 2 shows a perspective view of the completed product form.
- the result of having performed the evaluation test about the clad electrode manufactured by this embodiment is demonstrated.
- the spark plug electrode manufactured by conventional laser welding was also evaluated.
- this conventional laser welding method the base end surface of a cylindrical noble metal tip having the same shape as in the above embodiment is placed on the substrate surface, and the noble metal tip center is supported while supporting the noble metal tip with a predetermined support tool.
- the laser beam was intermittently irradiated to the outer periphery of the contact surface of the substrate and the noble metal tip while rotating about the axis line as the rotation axis.
- the laser beam output at this time was 3 to 5 J.
- the clad electrode of this example has a strength of 300 N or more, and the fracture surface is almost a sheared surface, so that there is no gap in the joint surface and the product is stable. There was found.
- 3A, B and 4 show cross-sectional observation photographs of the clad electrode after the thermal expansion / shrinkage test and the clad electrode by laser welding.
- 3A and 3B are a cross-sectional observation photograph (FIG. 3A) of the spark plug electrode having an unjoined portion on the outer peripheral surface of the joint portion and a cross-sectional observation photograph (FIG. 3B) of the spark plug electrode not having the unjoined portion. .
- the average length of unjoined portions of the spark plug electrode having unjoined portions was 40 ⁇ m on one side. From FIG. 3, in the cross section of the two clad electrodes of the present embodiment, the diffusion layer at the bonding interface has a substantially uniform thickness, and the bonding interface is substantially flat. Then, it was found that the noble metal tip (upper side of the observed cross-sectional photograph) and the base material (lower side of the observed cross-sectional photograph) were joined without generation of cracks or voids.
- FIG. 5 is a cross-sectional observation photograph after a thermal cycle of a spark plug electrode having no unbonded portion.
- Example 2 As Example 2, the same material as that of Example 1 was prepared. As pre-joining conditions, the applied pressure was 7 kgf, the output was reduced to 1110 A from the resistance welding conditions of Example 1, and the energization time was 100 msec. And the clad electrode which carried out the diffusion joining process of the heat processing conditions (1100 degreeC * 1 hour) same as Example 1 was produced. The characteristics of the clad electrode of Example 2 were the same as those of Example 1.
- Example 3 As Example 3, a clad electrode subjected to diffusion bonding treatment at 1200 ° C. for 1 hour with the same pre-bonding conditions as in Example 2 and the subsequent heat treatment condition changed to a high temperature side with the same combination of materials as in Example 2 Produced. When the cross section of the clad electrode of Example 3 was observed, the diffusion layer was 50 ⁇ m.
- Example 4 As Example 4, a clad electrode was fabricated by diffusion bonding treatment at a subsequent heat treatment condition of 1100 ° C. ⁇ 2 hours as the same pre-joining conditions as in Example 2 with the combination of materials shown in Example 2. When the cross section of the clad electrode of Example 4 was observed, the diffusion layer was 40 ⁇ m.
- Example 5 As Example 5, the same material as that of Example 1 was prepared. As pre-joining conditions, the pressure was 7 kgf, the output was 1400 A higher than the resistance welding conditions of Example 1, and the energization time was 4 msec. Then, a clad electrode subjected to diffusion bonding treatment at 1200 ° C. for 4 hours was produced. When the cross section of the clad electrode of Example 5 was observed, the diffusion layer was 90 ⁇ m.
- Example 6 As Example 6, a tape-like base material 1 having a thickness of 0.3 mm made of a Cu—Ni 30% alloy, which is a different material from that of Example 1, and a Pt—Ir 20% alloy having a diameter of 1.0 mm and a thickness of 0.3 mm. A columnar noble metal tip consisting of the above was prepared, and the pre-bonding conditions were the same pressure of 7 kgf, 600 A, the output being reduced from the resistance welding conditions of Example 1, and the energization time was 200 msec. Then, a clad electrode subjected to diffusion bonding treatment at 900 ° C. for 3 hours was produced. When the cross section of the clad electrode of Example 6 was observed, the diffusion layer was 10 ⁇ m.
- the clad electrodes of Examples 2 to 6 described above were subjected to the same peel test, thermal expansion, and shrinkage test as in Example 1. As a result, all of the clad electrodes had very excellent characteristics. As a result, within the range of appropriate manufacturing conditions, even if some conditions are changed on the production line, the characteristics of the clad electrode are not maintained at a practical level, and the quality control conditions are easy to control. Turned out to be.
- the joining of the noble metal tip and the base material can be reliably maintained and the life of the spark plug can be extended, the noble metal can be used efficiently and resources can be saved. .
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Abstract
Description
まず、図1Aに示すように、Ni-Ir1%合金からなる、厚さ0.3mmのテープ状基材1に、径1.0mm、厚み0.3mmのPt-Rh20%合金からなる円柱状の貴金属チップ2を、基材に対して垂直になるように当接配置した。この貴金属チップ2を、テープ状基材1の表面に当接する際、基材に対して貴金属チップが垂直になっていること、貴金属チップの当接した面と基板表面との間に隙間や、片当たりなどの状態が生じていないようにした。
実施例2として、実施例1と同じ材料を準備し、予備接合条件として、加圧力は同じ7kgfで、実施例1の抵抗溶接条件より出力を低下させた1110Aとし、通電時間を100msecにした。そして、実施例1と同一の熱処理条件(1100℃×1時間)の拡散接合処理をしたクラッド電極を作製した。この実施例2のクラッド電極の特性は、実施例1と同じ特性を有していた。
実施例3として、実施例2と同様な材料の組み合わせで、実施例2と同じ予備接合条件として、その後の熱処理条件を高温側へ変化させた1200℃×1時間で拡散接合処理したクラッド電極を作製した。この実施例3のクラッド電極における断面観察を行ったところ、その拡散層は50μmであった。
実施例4として、実施例2に示す材料の組み合わせで、実施例2と同じ予備接合条件として、その後の熱処理条件を1100℃×2時間で拡散接合処理したクラッド電極を作製した。この実施例4のクラッド電極における断面観察を行ったところ、その拡散層は40μmであった。
実施例5として、実施例1と同じ材料を準備し、予備接合条件として、加圧力は同じ7kgfで、実施例1の抵抗溶接条件より出力を高くした1400Aとし、通電時間を4msecにした。その後の熱処理条件を1200℃×4時間で拡散接合処理したクラッド電極を作製した。この実施例5のクラッド電極における断面観察を行ったところ、その拡散層は90μmであった。
実施例6として、実施例1とは異なる材質であるCu-Ni30%合金からなる、厚さ0.3mmのテープ状基材1に、径1.0mm、厚み0.3mmのPt-Ir20%合金からなる円柱状の貴金属チップを準備し、予備接合条件として、加圧力は同じ7kgfで、実施例1の抵抗溶接条件より出力を低下させた600Aとし、通電時間を200msecにした。その後の熱処理条件を900℃×3時間で拡散接合処理したクラッド電極を作製した。この実施例6のクラッド電極における断面観察を行ったところ、その拡散層は10μmであった。
2 貴金属チップ
3 抵抗溶接用の電極
6 拡散層
10 クラッド電極
Claims (8)
- 点火プラグの先端部分に配置される貴金属チップと、該貴金属チップが接合される基材とからなる点火プラグの電極に用いられる点火プラグ用クラッド電極において、
貴金属チップと基材との接合界面が略平面であることを特徴とする点火プラグ用クラッド電極。 - 貴金属チップと基材との接合部分には、5μm~100μm厚みの拡散層が形成されていることを特徴とする請求項1記載の点火プラグ用クラッド電極。
- 貴金属チップと基材との接合部分の外周表面に未接合部分を有し、前記未接合部分の長さが貴金属チップの半径に対して1/5以下である請求項1又は請求項2に記載の点火プラグ用クラッド電極。
- 貴金属チップは、Pt合金またはIr合金である請求項1~請求項3のいずれかに記載の点火プラグ用クラッド電極。
- 基材は、Ni合金またはCu合金である請求項1~請求項4のいずれかに記載の点火プラグ用クラッド電極。
- 請求項1~5いずれかに記載の点火プラグ用クラッド電極に用いる点火プラグ用クラッド電極材料であって、
基材の表面に、略円柱状の貴金属チップの接合面を当接し、
抵抗溶接により、基材表面に貴金属チップを予備接合し、熱処理により、基材と貴金属チップとを拡散接合することにより、基材と貴金属チップとが一体となった点火プラグ用クラッド電極材料。 - 基材の表面に、略円柱状の貴金属チップの接合面を当接し、
抵抗溶接により、基材表面に貴金属チップを予備接合し、基材と貴金属チップとが一体となった部分を打ち抜き加工し、
熱処理により、基材と貴金属チップとを拡散接合することによりクラッド電極を形成することを特徴とする請求項1~請求項4いずれかに記載の点火プラグ用クラッド電極の製造方法。 - 予備接合の抵抗溶接条件は、加圧力5~10kgf、溶接電流500~1500A、通電時間2~200msecであり、
拡散接合の熱処理条件は、真空雰囲気、還元雰囲気、不活性雰囲気のいずれかの雰囲気中で、加熱温度800~1200℃、処理時間1~5時間である請求項7に記載の点火プラグ用クラッド電極の製造方法。
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EP12818380.3A EP2738890A4 (en) | 2011-07-28 | 2012-07-24 | PLATED ELECTRODE FOR A SPARK PLUG AND MANUFACTURING METHOD THEREFOR |
KR1020147004845A KR101562151B1 (ko) | 2011-07-28 | 2012-07-24 | 점화 플러그용 클래드 전극 및 그 제조 방법 |
CN201280037882.8A CN103765708A (zh) | 2011-07-28 | 2012-07-24 | 火花塞用包层电极及其制造方法 |
US14/163,702 US20140184054A1 (en) | 2011-07-28 | 2012-07-24 | Clad Electrode for Spark Plug and Method For Manufacturing Same |
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WO2016043130A1 (ja) * | 2014-09-19 | 2016-03-24 | 田中貴金属工業株式会社 | 点火プラグ用電極を製造するためのクラッド構造を有するテープ材 |
US9368943B2 (en) | 2013-03-12 | 2016-06-14 | Federal-Mogul Ignition Company | Spark plug having multi-layer sparking component attached to ground electrode |
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DE10252736B4 (de) * | 2002-11-13 | 2004-09-23 | Robert Bosch Gmbh | Zündkerze |
US7804232B2 (en) * | 2004-01-27 | 2010-09-28 | Ngk Spark Plug Co., Ltd. | Spark plug with high durability |
CN101670488A (zh) * | 2009-02-05 | 2010-03-17 | 株洲湘火炬火花塞有限责任公司 | 一种贵金属火花塞电极的激光焊接方法 |
JP4964281B2 (ja) * | 2009-09-11 | 2012-06-27 | 日本特殊陶業株式会社 | スパークプラグ |
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2012
- 2012-07-24 EP EP12818380.3A patent/EP2738890A4/en not_active Withdrawn
- 2012-07-24 WO PCT/JP2012/068656 patent/WO2013015262A1/ja active Application Filing
- 2012-07-24 JP JP2013525719A patent/JPWO2013015262A1/ja active Pending
- 2012-07-24 US US14/163,702 patent/US20140184054A1/en not_active Abandoned
- 2012-07-24 KR KR1020147004845A patent/KR101562151B1/ko not_active IP Right Cessation
- 2012-07-24 CN CN201280037882.8A patent/CN103765708A/zh active Pending
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JPS58121583A (ja) * | 1982-01-14 | 1983-07-19 | 株式会社デンソー | 内燃機関用スパ−クプラグ |
JPH02312176A (ja) * | 1989-05-25 | 1990-12-27 | Nippondenso Co Ltd | スパークプラグ用電極の製造方法 |
JPH03225784A (ja) * | 1989-12-27 | 1991-10-04 | Nippondenso Co Ltd | 内燃機関用スパークプラグ |
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Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9368943B2 (en) | 2013-03-12 | 2016-06-14 | Federal-Mogul Ignition Company | Spark plug having multi-layer sparking component attached to ground electrode |
WO2014189088A1 (ja) | 2013-05-21 | 2014-11-27 | 株式会社デンソー | 内燃機関用のスパークプラグの製造方法 |
WO2016043130A1 (ja) * | 2014-09-19 | 2016-03-24 | 田中貴金属工業株式会社 | 点火プラグ用電極を製造するためのクラッド構造を有するテープ材 |
JP2016062825A (ja) * | 2014-09-19 | 2016-04-25 | 田中貴金属工業株式会社 | 点火プラグ用電極を製造するためのクラッド構造を有するテープ材 |
US9806500B2 (en) | 2014-09-19 | 2017-10-31 | Tanaka Kikinzoku Kogyo K.K. | Tape material having clad structure for manufacturing ignition plug electrode |
US10312669B2 (en) | 2016-01-26 | 2019-06-04 | Ngk Spark Plug Co., Ltd. | Spark plug |
Also Published As
Publication number | Publication date |
---|---|
EP2738890A1 (en) | 2014-06-04 |
US20140184054A1 (en) | 2014-07-03 |
KR101562151B1 (ko) | 2015-10-20 |
CN103765708A (zh) | 2014-04-30 |
EP2738890A4 (en) | 2015-04-01 |
JPWO2013015262A1 (ja) | 2015-02-23 |
KR20140041891A (ko) | 2014-04-04 |
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